Shingle of the wide-spaced type



P 1935- c. R. ECKERT 2,013,556

SHINGLE OF THE WIDE SPACED TYPE Filed July 24, 1931 l/1'86 B fauna 4 4,; Cow-.seB 7 44 INVENTOR [/are/Ice R L C ferf A'ITORN E Patented Sept. 3, 1935 UNITED STATES 2,013,558 snmcnn or run WIDE-SPACE!) ms:

Clarence B. Eckert, Englewood, N. 8., assignorto The Barrett Company, New York, N. E, a corporation of New Jersey Application July 24, 1931, Serial No. 552,899

2 Claim.

This invention is directed to roof, wall and other surface coverings and relates more particularly to thick butt shingles adapted to be laid in wide spaced relation.

It is an object of the present invention to provide a thick butt shingle of the felt base type which is provided with a coating of waterproof material, such as asphalt or other bituminous material, a surfacing of granular material on one face of the coating, an additional coating of waterproof material on the surfacing and a second surfacing of granular material applied to the second coating. The initial coating and surfacing cover the entire face of the shingle and the second overlay coating and surfacing cover the entire face except at marginal portions at the sides thereof in which the initial layer of coating and surfacing material is exposed. The marginal portions terminate on a transverse line spaced from the butt edge of the shingle.

It is a further object of the present invention to provide an improved roof covering by the application of thick butt shingles of the abovedescribed type in wide spaced relation in overlapping courses. The marginal portions of shingles of one course function'to indicate the proper position of the shingles of the overlying course and thus serve as aligning guides and assist in the ready and accurate application of the shingles on the roof or other surface. In the laying of the shingles, the side edges of the shingles of one course are laid in abutting relation with the inner edges of the marginal portions of the underlying pair of shingles. Preferably, but not necessarily, the second overlay coating and surfacing is made of an aggregate thickness equal to that of the base of the shingle including the initial coating and surfacing. Hence, when two courses of shingles are associated in the manner indicated, the top of the intermediate thick portion of the shingles of an underlying course lies in the same plane as the top of the marginal or thin portions of the shingles of an immediately overlying course and provides a plane surface support for the forward edges of the shingles laid to overlie those in the aforementioned overlying course. Thus, all tendency ,of the overlapping portions of, the overlying shingles to sag is prevented. Further, the thickened intermediate of the elements.

sun a further object of this invention is to provide a process whereby shingles of the abovedescribed type may be conveniently, eiliciently and quickly manufactured in a continuous manner.

The shingle embodying the principles of the present invention is preferably of general rectangular shape and is formed from a web or sheet of conventional roofing felt impregnated and coated with an asphaltic or bituminous composition and surfaced with crushed slate, gravel, slag, silica or other mineral material, hereinafter termed grit. A second layer of coating mao terial, such as asphalt or other bituminous material, is applied to the entire'surface of the coated and surfaced web with the exception of predetermined areas in which the initial surfaced coating is left uncoated. While this second coating is still soft and plastic, grit, either of the same color or fineness or of a different color or fineness from the first layer of grit, is then showered onto the web and adheres only to the cementitlous second layer of coating material applied. The web is thereafter severed along longitudinal lines extending through the median lines of the areas of the web wherein the initial surfaced coating is exposed and ontransverse lines midway between said areas to formindividual thick butt shingles.

The individual shingles thus formed are provided with an initial layer of coating and surfacing material over substantially their entire f upper surface and a second layer of coating and surfacing material over substantially the entire surface of the shingle to be exposed and the re-- maining portion of the upper surface except at marginal areas disposed at the opposite transverse edges of the shingle, the marginal areas terminating on a transverse line spaced from the lower edge of the'shingle. The. marginal areaswhich are not provided with the secondary layers of coating material and grit form depressed areas relative to the remaining surface of the 40 shingle.- I

The individual shingles thus formed are adapt-- ed to be laid in wide spaced relation with other shingles in overlapping courses. When so laid, and considering any three courses from bottom to top of the roof, the depressed areas, 1. e., the marginal areas of adjacent shingles in the second course combine with the thick or elevated portion of the shingles'of an underlying or first course to provide a substantially plane surface support for the butt edges of the shingles of the third course overlapping the adjacent shingles. Hence, the butt edges of the shinglesv are disposed, and supported in one plane and not allowed to v sag. The thickened portion of the shingle of the the marginal edges of the shingles in the second course above to support the butt edges of the shingles in the third course above, seals the opening formed beneath the butt edge of the shingles in the third course and prevents the ingress of rain, snow and other erodents.

For a more detailed description of the present invention, reference is made to the accompanying drawing which, it will be understood, is illustrative of the preferred embodiment of the invention and is not intended to limit the scope of application of the invention to the precise embodiment shown.

In the drawing Fig. 1 is a side elevation showing, somewhat diagrammatically, apparatus for the manufacture of the shingle of this invention;

Fig. 2 is a detailed view of the coating roll employed for the application of. the second coating;

Fig. 3 is a plan view of the web from which the shingle of this invention is cut immefiately after it has been submitted to the second coating and surfacing operations;

Fig. 4 is a plan view of an individual shingle embodying this invention;

' the shingle;

Fig. 5 is an enlarged cross section of the shingle of Fig. 1 taken on the line 55 of Fig. 4 and showing the relation of the depressed and elevated portions on the upper or exposed face of Fig. 6 is a plan view of a portion of a roof covered with the shingles of my invention laid in wide spaced relation and in overlapping courses; and

,Fig. 7 is an enlarged section taken on the line l7 of Fig. 6 showing the shingles laid in wide spaced relation with the front edges of each shingle effectively sealed against the ingress of ,the elements.

With reference to Fig. 1, the shingle of the present invention is formed from a longitudinal sheet or web I I of conventional roofing felt or other fibrous material saturated or impregnated with anasphaltic or other bituminous composition. A seal-back coating l2 of asphalt or like material (Fig. 5) is applied to the rear surface of the saturated felt II to render the. felt waterproof and resistantto moisture. To prevent adherence to the seal-back coat I 2 of each shingle to adjacent shingles when packed or otherwise formed in bundles, a layer ll) of grit of comparatively fine particles such as flaked mica or sand is applied to the seal-back coat.

The saturated felt i I with its seal-back coat i2 and the grit layer l0 uppermost is passed between rollers i3 and I4 arranged in superposed relation, as shown in Fig. 1. Roller i4 is partially submerged in a tank i5 of asphalt or like bituminous material maintained in a liquid state. The bituminous material adhering to the roller l4 during its rotation in the tank. I! is transferred to the felt ii and forms an adhesive layer l'l thereon of uniform thickness by reason 0'! the pressure exerted by the roller ii. The position of the felt I l is now reversed by passing it around a guide roller it so that the surface bearing the adhesive layer I1 is uppermost. From the guide roller It, the felt passes beneath a hopper l8 charged with grit, which may be of one color or a mixture of colors. The grit is showereddn a thereon. The coated and surfaced felt is passed around guide rollers 22 and 21 so that any excess grit not adhering to the adhesive layer ll.

of the felt II will fall back into the hopper I 8 and become available for further application. Rollers 22 and23 function to press the grit layer 2| into coating i'l so that the grit particles will become partially embedded in the adhesive layer ll.

The thus surfaced and coated felt H may then be passed around a series of cooling rollers 24 to harden and set the coating layer l1 thereon, the grit layer 2| becoming firmly embedded therein. From the coating rollers 24, the base i i is again reversed'by means of suitable guide rollers and is passed between coating rollers 25 and 26. Roller 26 is partially submerged in a tank 21 containing asphalt or like bituminous materiaL'is rotatably mounted therein and is arranged to contact with the surfaced layer 2| of the felt base and applying coating material to selected or predetermined areas of the base. This selective application is due to the novel design of the roll 26, as shown in detail in. Fig. 2. Two circumferential series of interior rectangular shaped slots 28 are formed in spaced relation from each other and from the ends of the roll in the face thereof, the individual slots being equally spaced around the periphery of the roll. A circumferential series of rectangular shaped slots 29 of equal length but of one-half the width of slots 28 is formed in each end of the roll. It will be noted that the ends of the slots 28 and 29 are in alignment along lines rimning parallel to the axis of the roller 26. By reason of this arrangement of slots, coating material is transferred to the layer 2i of felt base Ii to form an adhesive or second coating layer 3i which has rectangular spaced areas 32 arranged in rows widthwise of the sheet, adjacent rows being spaced from each other through which areas 32,

the layer 2i of grit is visible. The design of the roll 26 will necessarily vary depending upon the width of the sheet from which the shingles are cut and-the dimensions of the shingles.

m the passage of the resultant coated felt beneath and adheres only to the adhesive'layer.

3i and not to the uncoated portions of layer 2i which are not cementitious. The thus surfaced sheet is then passed around press rolls 38 which serves to partially embed the grit layer 31 in the coating 3| and is then reversed in its passage about roll 38 to cause excess grit particles to fall back into hopper 34.

The felt base after having thus been twice coated and surfaced as above described, is cut as shown in Fig. 3 along transverse lines 38 which lie midway between the rectangular areas 32 having only the initial coating and surfacing thereon'and alon'g transverse lines 39 which pas midway through the rectangular areas 32. The felt II is also severed along longitudinal lines ll which pass through the longitudinal median lines of the rectangular areas 32. The cutting may be accomplished by a rotating cutting roll having the cutting knives arranged thereon.

Shingle 42, shown in detail in Figs. 4 and 5 is thus formed. It will be noted that the shingle is provided with the seal back coating i2 surfaced or dusted with a layer ll of com-- paratively fine grit or sand render it noneementitious. The opposite face of the shingle or the face which is intended to be uppermost when the shingle is laid is provided with a comparatively thick layer ll of asphalt or the like which is uniformly applied to the entire face of the shingle. The layer 2| of grit is pressed therein to some extent to partially embed the grit particles therein and obtain a comparatively level surface.

The second layer 3| of coating material completely covers the end 43 of the shingle 42 which is intended to be exposed and also covers the remaining portion of the upper surface of the shingle with the exception of marginal areas 44 and 45 which extend along the transverse side edges of the shingle from the upper edge thereof to a transverse line spaced from and substantially parallel to the lower edge thereof. Thus it will be noted that the marginal areas 44 and 45 are relatively depressed with respect to the remaining surface of the shingle, which relation functions in the laying of the shingle in a manner to be hereinafter described. Preferably, but not'necessarily, the second or overlay coating of asphalt or other bituminous material is made thicker than the initial coating layer l1 and coarser grit particles are used for surfacing the second coating than those applied to the initial coating, so that the aggregate thickness of the second coating and surfacing is approximately equal to the thickness of the coated and surfaced felt base.

The mannerof laying the shingle of my invention is best explained by reference to Figs. 6

and 7 wherein individual shingles are shown laid on a portion of a roof, the shingles being laid in wide spaced relation in overlapping courses. with particular reference to courses A, B and C of Fig. 6, the individual shingles of course C are laid in spaced relation such that each individual shingle of course B will fit within the depressed marginal areas 44 and 45 of two adjacent shingles of course C, thereby being positively and accurately aligned both horizontally and vertically with reference to the roof and adjacent courses of shingles. Each individual shingle of course A is laid in a like manner by means of the depressed marginal areas 44 and 45 in the adjacent shingles of course B It will be noted that the upper or unexposed surface of each shingle of course C lies in substantially the same plane as the depressed marginal areas 44 and 45 of the shingles of course B so that the lower or exposed end of each shingle of course A rests on a substantially plane supporting surface indicated by the reference numeral 5| in Fig. 7. The upper thickened portions of the shingles of course C- not only support the shingles of course A so as to prevent sagging thereof, but also effectually seal the opening which would otherwise be formed by the butt end of the shingles of course A bridging the space between adJacent shinglesof course B.

The longitudinally extending area of the second layer 3 of coating material and the second layer 31 of surfacing material applied to each shingle further serve to strengthen the shingles and provide a more rigid strudture resistant to sagging tendencies and which assists ticed throughout the roof or other surface to be covered.

Grit or surfacing material may be omitted from the areas '44 and 45 of the shingle or the first layer ii of surfacing material entirely omitted, leaving the coating l'l exposed on the depressed marginal areas 44 and 45. Thus, when the shingles are laid, as shown in Figs. 6 and 7, the coating material upon the areas 44 and 45 will adhere to the contacting areas of overlying shingles and more efliciently seal the joint bebetween adjacent shingles. If desired, cementitious material such as bitumen may be applied to the depressed portions 44 and 45 to cause the overlying shingles to bond therewith. Grits of difierent colors may be applied to the individual shingles to obtain different color effects.

This invention comprehends shingles formed from other than a felt base. For example, shingles of a molded type composed of cement asbestos or clay, pitch or mastic compositions may be formed in the shape of the shingle and laid in the manner described herein.

The advantages of the shingles of my invention are readily apparent. The thickened exposed end and intermediate portions of the shingle results in increased rigidity, improved weathering properties and artistic deep shadow effects, particularly as compared with the flexible shingles now marketed. Laying the shingle in wide spaced relation as shown in Fig. 6 with approximately two-thirds of the shingle exposed results in a marked economy in the number of shingles necessary to cover a given surface.

7 layers of the shingle along the bending lines.

It is tohe understood that my invention is not restricted to the present disclosure.

I claim:

l. A shingle of the wide spaced type adapted to be laid in overlapping courses with other like shingles comprising a flexible fibrous base coated with bituminous material, said shingle having a second layer of coating material applied thereto except on marginal areas at the sides thereof. said areas extending from the upper end of the shingle to a transverse line spaced from the lower end thereof a distance equal to the amount of the shingle exposed by the overlapping shingles of an overlying course, granular surfacing matem1 partially embedded in said second coating layer whereby the top surface of said shingle except said marginal areas lies in one plane and the surface of said marginal areas lies in another plane below said first plane, said marginal areas being of a thickness equal to about onethe thiemess of the contiguous portions of the shingle whereby overlapping marginal areas of two shingles form with contiguous portions of the shingles a substantially plane supporting surface for-a third shingle for preventing sagging thereof. Y

2. A roof composed of shingles laid in wide spaced relation in overlapp ng courses, each The feature of having the intermediate thick portio shingle comprising a fibrous base-having one surface coated with bituminous material and grit particles partially embedded in said bituminous material, a second layer of bituminous material completely covering said grit particles except at marginal areas at the sides thereof, said areas extending from the upper end of the shingle to a transverse line spaced from the lower end thereof a distance equal to the amount of the shingle intended to be exposed by the overlapping. shingles of an overlying course, and a second layer of grit partially embedded in said second coating, the combined thickness of said second coating layer and said second layer of grit being substantially equal to the combined thickness of said fibrous base and said first coating and surtacing layers, said first surfacing layer lying in a plane below said second surfacing layer, the

shingles of each course being laid in wide spaced I relation such that marginal areas of a pair 0! shingles of each course receive the side edges of an overlying shingle in the course immediately above; the marginal areas 01' the shingles oi the overlying course and a portion of the shingles of the underlying course presenting a substantially plane support tor the shingles in the course overlapping the said overlying course.

CLARENCE R. 

